Warm Forming of Al, Ti and Mg alloy Sheet ppt

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ERC
NSM
Research & Development Update
Warm Forming of Al, Ti and Mg alloy Sheet
Engineering Research Center for Net Shape Manufacturing (ERC/NSM)
www.ercnsm.org
The Ohio State University
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ERC
NSM
Background
 A fundamental understanding of warm forming of Al, Ti and Mg
alloys will benefit various industries (automotive, aerospace,
defense, electronics, medical etc.).
 Technology for Warm forming of Al, Ti and Mg alloy sheets is
developed (in co-operation with University of Virginia, University
of Darmstadt (Germany), University of Hanover (Germany), Aida
Dayton Technologies, support by NSF).
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1. Use FE modeling and experiments to determine,
1. material properties (elevated temperature hydraulic bulge test and property
variation within sheet and tube).
2. tool design guidelines
(minimum punch & die radii, optimum heating
techniques).
3. process design guidelines
(BHF, forming velocity, optimum tool
temperatures, lubrication, loading paths).

2. Implement results in industrial applications.
Objectives
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p
h
d
d
h
t
d
t
0
R
h
R
d
F
c
F
c
Warm Forming of Al, Ti and Mg
Alloy Sheets
Material properties for Mg alloy using submerged hydraulic bulge tool
Material: AZ31-O Mg alloy
Thickness (t
0
): 1.2 mm
Initial Sheet

Bulged Sheet
Tooling at Univ. of Darmstadt, Germany
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Deformation of AZ31-O Mg alloy
sheet at 225
o
C
Bulge Height : 12mm
Bulge Height : 40 mm
Deformation of AZ31-O Mg alloy
sheet at room temperature
Elevated temperature hydraulic bulge test is used to obtain stress-strain curves at
various temperature and strain rates under biaxial state of deformation
Warm Forming of Al, Ti and Mg
Alloy Sheets
Material properties for Mg alloy using submerged hydraulic bulge tool
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ERC
NSM
Warm Forming of Al, Ti and Mg
Alloy Sheets
Tool and process design guidelines to improve formability
Aida Servo Press (used in warm forming of Al, Mg and Ti sheet)
Power Source Balancer tank
Main gear
Servomotor
Capacitor
Drive Shaft

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Stage 1
Stages in warm deep
drawing
Warm Forming of Al, Ti and Mg
Alloy Sheets
Tool and process design guidelines to improve formability
Stage 2
Stage 3
AIDA tooling
to warm form
Al, Mg and Ti
alloy sheet
Heated tool
Cooled punch
Die Holder
Upper Tool
Die Ring
Lower Tool
Cartridge Heaters
Blank Holder
Punch
Cartridge Heaters
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ERC
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Warm Forming of Al, Ti and Mg
Alloy Sheets

Warm deep drawing tool in the press
AIDA NC 110 ton
servo press
Tool and process design guidelines to improve formability
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ERC
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Warm Forming of Al, Ti and Mg
Alloy Sheets
AL 5754- O
2.5250
2.1RT
2.9300
LDRT (
o
C)
2.5275
2.1RT
2.9275
LDRT (
o
C)
AL 5052-H32
Preliminary results (Velocity range : 5-50mm/sec)
Process parameters/ FE Simulation / Rectangular cup / Ti alloy parts
Note : RT: Room temperature, LDR : Limit draw ratio
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ERC
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Warm Forming of Al, Ti and Mg

Alloy Sheets
2.6275
-RT
3.2275
LDRT (
o
C)
Mg AZ31-O
Preliminary results (Velocity range : 5-50mm/sec)
Process parameters/ FE Simulation / Rectangular cup
Note : RT: Room temperature, LDR : Limit draw ratio
2.5310
LDRT (
o
C)
Ti (Grade 1)
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Warm Forming of Al, Ti and Mg
Alloy Sheets
Status
1) Experimental work and analysis are in progress
2) Several graduate students (PhD/MSc) are working on this project
We are continuously looking for;
a) industry cooperation and potential application of technology
for new product development
b) industry support, suggestions and interest are most welcome
Contact: Serhat Kaya, PhD Student (
, 614-292-1785)

Prof. Taylan Altan, (
, 614-292-5063)